System and method for error correction in angular position sensors

ABSTRACT

A system and method for controlling a rotating E-machine and for correcting a rotational position signal output by an angular position sensor operatively connected to the E-machine in conjunction with a sensor digital converter is disclosed. For each angular operating speed of interest, a set of signals as a function of position is taken such that the harmonics (or sub-harmonics) related to the position sensor may be determined and isolated from errors due to an associated digital converter. From this information, the magnitude and phase of the position sensor harmonics is determined. The effects of the sensor digital converter (or other signal processing equipment) are then determined and accounted for, allowing the control system to apply the total position error signal to the position sensor output signal to determine a corrected position sensor signal for use in controlling the E-machine.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.14/621,498 filed Feb. 13, 2015, which claims the benefit ofInternational Application No. PCT/US2013/032064 filed Mar. 15, 2013,which claims the benefit of U.S. Provisional Patent Application No.61/691,482 filed Aug. 21, 2012, the entire disclosures of which arehereby incorporated by reference.

BACKGROUND

The present invention generally relates to monitoring and control ofrotating machinery and, more particularly, to a system and method forperforming error correction in rotor position signals received fromangular position sensors, such as resolvers.

Many vehicle drive systems, such as those present in electric and hybridvehicles, use a rotating electric machine, such as a permanent magnet(PM) machine, to help direct power to the vehicle transmission andwheels. In order to accurately and efficiently perform dynamic torquecontrol of the rotating electric machine, an angular position sensor istypically used to determine the angular position of the rotor. Theposition sensor, which often comprises a rotating electrical transformerdevice known as a resolver, is susceptible to a variety of error sourcesthat can reduce the overall system performance. For example, mechanicalerrors can be introduced when centering the rotor of a resolver relativeto its stator during assembly. In addition to mechanical tolerances,errors can be introduced during the processing of the position sensoroutput signals, such as when the finite bandwidth of ananalog-to-digital converter changes the spectral behavior of thesignals.

In certain applications, the system is designed to accept such error andthe resulting reduction in performance is tolerated. If the reduction inperformance is not permissible, digital filtering techniques can be usedto attempt to filter the error. However, known filtering techniques areoften inadequate and may cause additional undesirable phase shift andlag effects.

An improved technique for correcting errors in the position sensoroutput is therefore needed which will dynamically learn the positionerror associated with a position sensor and correct for such error whenthe system is used in its intended application.

SUMMARY

According to one aspect of the present disclosure, a system is presentedfor controlling a rotating E-machine and for correcting a rotationalposition signal output by an angular position sensor operativelyconnected to the E-machine in conjunction with a sensor digitalconverter. For each angular operating speed of interest, a set ofsignals as a function of position is taken such that the harmonics (orsub-harmonics) related to the position sensor may be determined andisolated from errors due to an associated digital converter. From thisinformation, the magnitude and phase of the position sensor harmonics isdetermined. The effects of the sensor digital converter (or other signalprocessing equipment) are then determined and accounted for, allowingthe control system to apply the total position error signal to theposition sensor output signal to determine a corrected position sensorsignal for use in controlling the E-machine.

According to another aspect, a system for controlling a vehicledrivetrain is presented, comprising a rotating E-machine operativelyconnected to the vehicle drivetrain, an angular position sensoroperatively connected to the rotating E-machine and producing a sensoroutput signal, a sensor digital converter operatively connected to theangular position sensor, the sensor digital converter receiving saidsensor output signal and producing a converter output signal, and acontroller operatively connected to the sensor digital converter. Thecontroller operates the E-machine at a first angular speed, compensatesfor a first error in the converter output signal, said first error dueto the angular position sensor, and further compensates for a seconderror in the converter output signal, the second error due to the sensordigital converter.

According to another aspect, a method for controlling a vehicledrivetrain is presented comprising rotating an E-machine, the E-machineoperatively connected to an angular position sensor, measuring a firstsignal generated by an angular position sensor operatively connected tothe E-machine, storing data representing the first signal over at leastone electrical cycle, compensating an output signal for the effects ofboth a first error due to the angular position sensor and a second errordue to the effects of a sensor digital converter operatively connectedto the angular position sensor.

Further forms, objects, features, aspects, benefits, advantages, andembodiments of the present invention will become apparent from adetailed description and drawings provided herewith.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a hybrid drive control system accordingto one embodiment of the present disclosure.

FIG. 2 is a diagram showing the gain component of the transfer functionof a resolver to digital converter according to one embodiment of thepresent disclosure.

FIG. 3 is a diagram showing the phase shift component of the transferfunction of a resolver to digital converter according to one embodimentof the present disclosure.

FIG. 4 is a diagram showing the relationship between motor speed andspeed error for a variety of harmonics of the speed.

FIG. 5 is a diagram which illustrates the stages involved in correctingposition sensor errors in the system of FIG. 1 according to oneembodiment.

DESCRIPTION OF THE SELECTED EMBODIMENTS

For the purpose of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings, and specific language will be used to describe the same.It will nevertheless be understood that no limitation of the scope ofthe invention is thereby intended. Any alterations and furthermodifications in the described embodiments and any further applicationsof the principles of the invention as described herein are contemplatedas would normally occur to one skilled in the art to which the inventionrelates. One embodiment of the invention is shown in great detail,although it will be apparent to those skilled in the relevant art thatsome features not relevant to the present invention may not be shown forthe sake of clarity.

FIG. 1 shows a diagrammatic view of a vehicle hybrid drive controlsystem 100 according to one embodiment of the present disclosure. Thecontrol methods described herein are applicable to any type of electricor hybrid vehicle drive which incorporates a rotating electric machine(E-machine). As shown, the system 100 includes an inverter 110, anenergy storage system (ESS) 112, an E-machine 120, an angular positionsensor, illustrated here as resolver 130, a sensor digital converter,illustrated here as resolver-to-digital converter (RDC) 140, an errorcorrection controller 150, and a motor controller 160.

In order to provide adequate control of the E-machine 120, the motorcontroller 160 must receive accurate angular position signals from theresolver 130 (via RDC 140). The RDC 140 is required to generate thesignals that excite the resolver and to demodulate the resolver's outputsignals so that a position estimate can be dynamically tracked andconverted into raw resolver format position signal output by theresolver 130. The resolver 130 and the RDC 140 each contribute aseparate component to the overall error, although the characteristics ofeach component are different. Most resolver-based errors are harmonic innature, and the magnitude of each position component is independent ofspeed, with the resulting speed error being proportional to speed, anattribute that is important. On the other hand, most RDC errors aredependent on speed, but do not vary proportionally with speed. If alarge number of samples are taken of the position signals over a varietyof speeds, the results can be analyzed to determine those harmonicswhich vary proportionally with speed and those which do not. Harmonicswhich do not vary with speed or vary proportionally with speed can bedetermined to be resolver related, allowing an equation for theresolver-related error signal to be determined. Likewise, a separateequation for the RDC error can be determined and combined with theresolver-related error equation to determine an overall equation for theexpected error. This information can then be used to compensate forerrors in the signal received by the motor controller 160.

In general operation, the motor controller 160 receives a desired torquecommand 162 from an external control system, such as an operatorthrottle control. Based on various inputs, including signals receivedfrom error correction controller 150, the motor controller 160 outputsgate signals 163 to the inverter 110. The inverter 110 converts DC powerfrom the ESS 112 into AC power signals 114 which drive the E-machine120.

Inverter 110 may comprise a DC-AC inverter which converts DC power fromthe ESS 112 into AC power for driving the E-machine 120. E-machine 120may comprise an electric motor, generator, permanent magnet machine, orany other type of electric rotating machine used to assist inpropelling, powering, or stopping a vehicle.

Resolver 130 preferably comprises a rotary angular position sensor, suchas a rotating electrical transformer having stator windings and optionalrotor windings, and configured to output position signals based on therelative angular position of the electromagnetized stator and rotorwindings when supplied with an excitation signal. RDC 140 comprises asine wave generator which supplies an excitation signal 131 to theresolver 130 and receives modulated analog signals 132 containing theposition information in return. RDC 140 demodulates the signals 132 anddynamically produces a position signal 142. It shall be understood thatthe resolver 130 and the RDC 140 may be provided as a single unit or asseparate components. In certain embodiments, the functionality of theRDC 140 may be included within the error correction controller 150 orthe motor controller 160.

The motor controller 160 is in operative communication with varioussensors, actuators, transformers, and controllers in the vehiclepowertrain including, but not limited to, inverter 110 and errorcorrection control unit 150. In addition, the motor controller 160 mayreceive additional signals, such as voltage, current, phase,temperature, position, and/or other variables for the efficient controlof the system 100.

Error correction controller 150 is in operative communication with RDC140 and motor controller 160 and is configured to determine andcompensate for errors in the resolver position and RDC output signals.In certain embodiments, the error correction controller 150 may beincorporated within the motor controller 160.

In a typical embodiment, error correction controller 150 and the motorcontroller 160 may each include a computer having a processor, memory,and input/output connections. It shall be understood that additionalelements may be included in the motor controller 160 and errorcorrection control unit 150 as required by the particular application.It shall be further understood that the error correction controller 150may optionally share a processor and storage with the motor controller160 and/or may be provided in a separate physical housing or integratedas a single unit.

Resolver 130 is operably mounted to the E-machine 120 such that therotor of the resolver 130 rotates in unison with the rotor 122 of theE-machine 120 in order to sense the angular position of the E-machine120, while the stator of the resolver 130 is held stationary. As will beexplained in further detail below, the output 132 of resolver 130 is fedto RDC 140, which converts the resolver signals into a digitalrepresentation of the angular position. The output 142 of the RDC 140 isthen fed to error correction controller 150, which uses resolver errorcorrection block 154 to determine a resolver error signal 155. Theresolver error signal 155 is then inverted and combined with theoriginal signal 142 at block 156, and output as corrected positionsignal 158 to the motor controller 160 for use in determining the propergate signals 163.

An analysis of the error signals related to the resolver 130 and the RDC140 will now be presented. Starting with the errors from the resolver130, the resolver output signals 132 will typically include errors whichare harmonics of the angular velocity. These errors come from a varietyof sources, including resolver winding harmonics and mechanical effectssuch as lack of concentricity and run out. However, the underlyingposition error amplitude is generally independent of angular speed, anattribute that can be exploited as described further below.

Angular speed, or frequency (which is determined from angular position),is used as a control variable for higher order motor controlfunctionality such as dq cross-axis and flux decoupling. Therefore, theresolver position error can lead to significant problems for theE-machine controls.

The general equations relating the terminal voltage, current, and magnetflux of a permanent magnet machine (such as E-machine 120) in the rotorreference frame are shown below as equations (1) and (2).V _(qs) ^(r) =r _(s) I _(qs) ^(r) +pL _(qs) I _(qs)^(r)+ω_(e)(λ_(magnet) +L _(ds) I _(ds) ^(r))  (1)V _(ds) ^(r) =r _(s) I _(ds) ^(r) +pL _(ds) I _(ds) ^(r)−ω_(e) L _(qs) I_(qs) ^(r)  (2)

where:

-   -   V_(qs) ^(r)=q-axis voltage    -   V_(ds) ^(r)=d-axis voltage    -   I_(qs) ^(r)=q-axis current    -   I_(ds) ^(r)=d-axis current    -   L_(qs)=q-axis inductance    -   L_(ds)=d-axis inductance    -   r_(s)=stator resistance    -   λ_(magnet)=flux linkage of the magnet    -   ω_(e)=electrical frequency in radians/second    -   p=time derivative operator

The cross coupling terms, ω_(e)L_(qs)I_(qs) ^(r) and ω_(e)L_(ds)I_(ds)^(r), and the magnet flux linkage term, ω_(e)λ_(magnet), are generallydecoupled by the controller 160 in order to improve the overallcontroller performance. The electrical frequency term, ω_(e), is basedon the rotational frequency of the E-machine 120 and necessitates havingan accurate measurement of speed.

The relationship of the E-machine 120 mechanical rotational frequency tothe resolver 130 frequency is shown below in equation (3). Thecorresponding relationship of the E-machine 120 electrical frequency toE-machine 120 mechanical rotational frequency is shown in equation (4).θ_(ResolverElec)=(P _(resolver)/2)θ_(RotorMech)  (3)θ_(MachineElec)=(P _(motor)/2)θ_(RotorMech)  (4)

where:

-   -   θ_(RotorMech)=the E-machine mechanical angular position    -   θ_(MachineElec)=the E-machine electrical position    -   θ_(ResolverElec)=the resolver electrical position    -   P_(resolver)=the number of electrical poles of the resolver    -   P_(motor)=the number of electrical poles of the E-machine

In order to simplify the analysis, it may be assumed that P_(resolver)is equal to P_(motor), although this is not a requirement.

The harmonics of the resolver position error are generally of thegreatest concern since they lead to large variations in the speedestimate. For example, assume that the accuracy of the resolver 130 is+/−4 degrees, and the position error is at the 5^(th) harmonic of theresolver frequency. The measured position signal will be equal to:θ_(meas)(t)=θ(t)+4°(π/180°)sin(5ω_(e)(t)+φ₅)  (5)

where:

-   -   θ_(meas)(t)=the measured resolver position signal in electrical        radians at time t    -   θ(t)=the ideal resolver position signal at time t    -   ω_(e)=resolver frequency in radians/second    -   φ₅=the phase of the fifth harmonic of the resolver frequency        signal

Likewise, the measured speed signal of the resolver 130 in electricalradians/second will be:ω_(meas)(t)=ω_(e)(t)+4°(π/180°)5ω_(e) cos(5ω_(e)(t)+φ₅)  (6)

where:

-   -   ω_(meas)(t)=the measured resolver angular speed signal in        electrical radians/second at time t    -   ω_(e)(t)=the ideal resolver angular speed signal at time t    -   φ₅=the phase of the fifth harmonic of the resolver frequency        signal

In addition, the relationship of resolver speed in electricalradians/sec to revolutions per minute (RPM) can be expressed as:ω_(e)=(RPM)(2π/60)(P _(motor)/2)  (7)

where:

-   -   ω_(e)=resolver speed in electrical radians/second    -   P_(motor)=the number of motor poles    -   RPM=resolver speed in mechanical revolutions per minute

Therefore, equations (6) and (7) can then be combined to express therelationship between speed error and resolver-related position error as:RPM_(error)=θ_(error)π(N)(RPM)/180  (8)

where:

-   -   RPM_(error)=speed error in revolutions per minute    -   θ_(error)=resolver position error in degrees electrical    -   N=the harmonic order of the error    -   P=the pole number of the E-machine (assumed equal to resolver        pole number)

Applying equation (8), for a 4 degree resolver position error at the5^(th) harmonic of a 20 pole E-machine rotating at 3,000 RPM, theresulting speed error would be +/−1,047 RPM. Such a large error isunacceptable as it would lead to significant control issues andinstability. In addition, the basic position error will cause theinverter 110 to track the reported position variation, adjusting I_(d)and I_(q) currents in the motor control process as would be appropriate.This deviation in tracking results in undesirable torque pulsations, inaddition to problematic variations in voltage and current.

However, in addition to errors resulting from the resolver 130 itself,further error may be introduced by the RDC 140 which is used inconjunction with the resolver 130. The RDC 140 is required to demodulatethe position signals 132 from the resolver 130 and generate a digitalestimate 142 of the position signals 132. The output of the RDC 140 iseventually directed to the motor controller 160 and used for controllingtorque. As mentioned above, the RDC 140 has a unique set of spectralcharacteristics which must also be accounted for if error is to beminimized.

FIGS. 2 and 3 illustrate sample transfer functions for gain and phase,respectively, of a typical RDC, such as a model AD2S1205 resolver todigital converter manufactured by Analog Devices, Inc. of One TechnologyWay, P.O. Box 9106, Norwood, Mass. 02062-9106, U.S.A. FIG. 2 shows thegain function 206 and FIG. 3 shows the phase shift function 306. Thetransfer functions 206 and 306 illustrate how different frequencies aremodified by the characteristics of the RDC 140. For DC signals (0 Hz),which occur at a fixed RPM, the gain is unity (point 210) and the phaseshift is zero (point 310). However, for higher order harmonics, such asthose present in resolver harmonic error, there is a significant gainand phase shift. For example, points 220 and 320 respectively illustratethe a gain of approximately 0.6 and phase shift of approximately −120degrees-electrical at a frequency of 2×10³ Hz.

By combining the magnitude gain and phase shift associated with the RDC140 (FIG. 2 above) with that of the resolver 130 (Equation (8) above),the effect of the combined resolver/RDC system on position or speederror as a function of harmonic order can be determined. FIG. 4illustrates the results for speed (RPM) error magnitude as a function offrequency.

Unlike resolver-based errors, RDC-based errors are dependent upon speed(yet are not proportional to speed). While the impact of the 5^(th)harmonic resolver error is shown to be reduced when the entire system isconsidered, it is now also a function of speed which is not desirable.

If the effect of the RDC 140 is ignored initially, the underlyingposition error due to the resolver can be found by considering thespectral properties of the speed signal reported by the idealized RDC140. In the ideal case of a fixed speed and no error present, thespectral content of the speed signal from the resolver 130 should onlyexist at DC or zero Hz. In reality, the error must be found in thesystem which may have a dynamic load (pump) or source (engine).

In the case of an engine spinning at 600 RPM, the expected spectralcontent from the system would be as follows:

Frequency Source 0 Hz (DC) Ideal Speed Content 10 Hz MechanicalRotational Frequency 30-40 Hz Engine Firing Fundamental (6-8 cylinder)100 Hz Electrical (Machine and Resolver if 10 Pole Pair) 200 Hz Resolver2^(nd) electrical harmonic 240 Hz Resolver 24^(th) mechanical harmonic

FIG. 5 illustrates a method 500 for correcting position sensor outputsignals according to one embodiment. Starting with stage 510, thecontroller 160 directs the E-machine 120 (via inverter 110) to rotate atdifferent speeds over multiple electrical cycles. In certainembodiments, the E-machine 120 may be spun by an additional externalmotive device, such as an engine, that is also connected to the resolver130 rotor. At stage 520, the obtained resolver position and speed datais stored.

Turning to stage 530, a Fourier analysis is performed on the sampleddata. Assuming a sufficient number of position and speed samples, anadequate resolution of a Discrete Fourier Transform can be attained thatwould allow separating the various components of the error signal.Either position or speed (or both) can be used for the analysis, howeverspeed is a more convenient variable as it is a DC signal in the idealcase. In addition, angle-based signals are also more preferable (asopposed to time-based signals)since the error that must be corrected isa function of position, not time. If the resolver is spun at arelatively constant rate, a high speed sampling of the RDC 140 positionand speed signals can be performed. A fixed integer number of samplesper rotation or, alternatively a sufficiently high number of samples tominimize any windowing effects can then be taken so that approximatelyfixed angular sampling results. The relationship between speed andposition is shown in Equation (9) below.ω=Δθ/Δt  (9)

where:

-   -   ω=angular speed    -   Δθ=change in angular position    -   Δt=change in time

Therefore, a fixed time-based sample rate also provides a near constantangular sample rate, provided the speed is relatively fixed. Basicerrors, such as linear acceleration, can also be easily corrected iffixed speed cannot be guaranteed. Some speed variation due to otherdisturbances can be tolerated provided they are sufficiently smallcompared to the effect of the resolver 130 error. The speed samplestaken from the idealized RDC can then be converted into the Fourierfrequency domain at stage 530 as follows.

The basic Discrete Fourier Transform (DFT) equations are:

$\begin{matrix}{{A(k)} = {\frac{1}{N}{\sum\limits_{n = 0}^{N - 1}\;{{x(n)}{\mathbb{e}}^{{- j}\; k\frac{2\pi}{N}n}}}}} & (10) \\{{x(n)} = {\sum\limits_{n = 0}^{N - 1}\;{{A(k)}{\mathbb{e}}^{j\; k\frac{2\pi}{N}n}}}} & (11)\end{matrix}$

where:

-   -   k=the number of the harmonic order    -   N=the total number of samples    -   n=a particular sample within the set of samples    -   j=the imaginary unit    -   x(n)=speed waveform in the sampled-angle domain    -   A(k)=a complex number that indicates magnitude and phase for the        k^(th) harmonic order.

A typical position sensor, such as resolver 130, should have an expectedharmonic error pattern. For example, a resolver, due to its constructionand mounting arrangement would have spectral content at specificharmonics of the resolver frequency. By determining the magnitude andphase of these harmonics, the error at a particular speed can beestimated. Since resolver related speed harmonic amplitude should beproportional to speed for an idealized RDC 140, multiple readings atdifferent speeds can be taken to remove content associated with othersources (such as firing harmonics for an engine) which have amplitudesthat are speed dependent. Therefore, harmonics which do not varyproportional to speed can be determined to be unrelated to the resolver130.

The resulting magnitude and phase at different harmonics represent thecombined system effect. Using the inverse of the RDC 140 harmonic gainand phase of FIGS. 2 and 3, the effect of the RDC 140 can removed. Theremaining magnitude and phase at the different harmonics represents theerror pattern associated with the resolver 130 only and is consistentwith equation (8) above. Furthermore, FIG. 4 indicates speed rangeswhere various harmonics will have the greatest impact on the system,again demonstrating the need to perform measurements at various speedsfor maximum sensitivity.

By solving equation (8) for the position error for each harmonic orderN, the underlying position error can be extracted. Furthermore, thephase shift information can be adjusted by 90 degrees from the Fourieranalysis to account for the integral relationship relating speed toposition. This allows the formation of the underlying position errorsignal shown below.θ_(error)(θ)=A ₁ sin(θ+φ₁)+A ₂ sin(2θ+φ₂)+A ₃ sin(3θ+φ₃)+ . . . +A _(N)sin(Nθ+φ _(N))  (12)

where:

-   -   θ=angular position    -   A_(N)=magnitude of the position error θ_(error) at the Nth        harmonic    -   φ_(N)=phase of the position error at the Nth harmonic

By viewing the resolver error in this fashion, a simple equationcontaining the position error information due to the resolver 130 can bestored in the error correction controller 150.

Once the underlying resolver error has been found and stored as gain andphase adjustments for different harmonics, the process proceeds to stage540, where the position error equation is modified to incorporate theadditional gain and phase shift associated with the RDC 140 as shown inequation 13 below.θ_(error)(θ,RPM)=A ₁RDC₁(RPM)sin(θ+φ₁+φ_(RDC1)(RPM))+A₂RDC₂(RPM)sin(2θ+φ₂+φ_(RDC2)(RPM))+A ₃RDC₃(RPM)sin(3θ+φ₃+φ_(RDC3)(RPM))+. . . +A _(N)RDC_(N)(RPM)sin(Nθ+φ _(N)+φ_(RDCN)(RPM))  (13)where:

-   -   RDC_(N)(RPM)=the RDC gain associated with the Nth harmonic at a        specific speed    -   φ_(RDCN)(RPM)=the RDC phase associated with the Nth harmonic at        a specific speed

In the above example, RPM can be calculated from the corrected positionor can be taken from the corrected RDC speed information. As can be seenfrom FIGS. 2 and 3, modest error can be tolerated.

Due to the linear nature of the system, the error θ_(error)(θ,RPM) fromequation (13) can be subtracted from the original RDC position signal toform the correct position measurement. A speed signal can then bederived from the position signal. An equation for speed error can alsobe created as shown below in (14).ω_(error)(θ,RPM)=A ₁ω_(e)RDC₁(RPM)cos(θ+φ₁+φ_(RDC1)(RPM))+A₂2ω_(e)RDC₂(RPM)cos(2θ+φ₂+φ_(RDC2)(RPM))+A₃3ω_(e)RDC₃(RPM)cos(3θ+φ₃+φ_(RDC3)(RPM))+ . . . +A _(N) Nω_(e)RDC_(N)(RPM)cos(Nθ+φ _(RDCN)(RPM))  (14)

At stage 550, the information from equations (13) and (14) is determinedby the error correction controller 150 at each measured position θ todetermine the proper position error θ_(error) that should be subtractedto find the uncorrupted position signal as well as the speed errorω_(error) that should be subtracted from the measured speed.

At stage 560, the error information from stage 550 is stored either asindividual equations or stored in a data table, depending on the needsof the particular application. During operation, the error correctioncontroller is able to refer to the stored information to adjust thesignal 158 being reported to the motor controller 160 to correct for theexpected position error.

It shall be understood that sub-harmonics may also be detected andcorrected using the same methodology. Multiple electrical cycles arerequired to be stored and some form of absolute position tracking (onceper rotation—such as provided by an engine crank sensor) is necessary inthat case. This tracking can be in the form of a sensor, an algorithmthat runs each time the processor is powered on or an algorithm thatstores and dynamically checks the validity of the assumed absoluteposition value each time the processor power is cycled.

In certain embodiments, additional signals may be measured to correctfor actual variation in the driven speed of the E-machine 120. If thed-axis and q-axis currents are zero, or regulated to zero, then thephase electro-motive force (EMF) can be either directly or indirectlymeasured. A Fourier Transform of the EMF signal can then be taken todetermine the specific harmonics which are actually occurring in theapplication (such as engine firing harmonics), and may be used todiscern actual speed variation from resolver error. As used herein, theterm “actual” shall be interpreted to refer to signal content resultingfrom operation of the E-machine and which is not induced by the resolver130 or the RDC 140. For example, if variation in the magnitude of theEMF is observed at the engine firing fundamental frequency, ω_(N), theactual speed variation can be determined from the harmonic magnitude andphase of the EMF as follows:

Given the speed variation at the Nth harmonicω=ω₀ +Nαω ₀ cos(Nω ₀ t+φ _(N))  (15)

where:

-   -   t=time    -   N=the harmonic order number    -   ω₀=average speed of the motor    -   ω=engine speed with harmonic variation    -   α=Nth harmonic positional magnitude (radians)    -   φ_(N)=Nth harmonic speed phase (radians)

The EMF can be calculated as:EMF=EMF₁(1+Nα cos(Nω ₀ t+φ _(N)))sin(ω₀ t+α sin(Nω ₀ t+φ _(N)))  (16)

where:

-   -   EMF₁=the fundamental component of EMF at speed, ω₀

The above expression for EMF can be translated into the frequency domainand shown to have components of EMF at two harmonic orders, N−1, andN+1. That which occurs at the N−1 order will have a magnitude of:

$\begin{matrix}{{EMF}_{N - 1} = {{{EMF}_{1}\left( \frac{N - 1}{2} \right)}\alpha}} & (17)\end{matrix}$

Likewise, the EMF for the N+1 order harmonic will have a magnitude of:

$\begin{matrix}{{EMF}_{N + 1} = {{{EMF}_{1}\left( \frac{N + 1}{2} \right)}\alpha}} & (18)\end{matrix}$

The actual speed magnitude can be found from (17) and (18) to be:

$\begin{matrix}{\omega_{N} = {{\omega_{0}N\;\alpha} = {{\omega_{0}{N\left( \frac{{EMF}_{N - 1}}{{EMF}_{1}} \right)}\left( \frac{2}{N - 1} \right)} = {\omega_{0}{N\left( \frac{{EMF}_{N + 1}}{{EMF}_{1}} \right)}\left( \frac{2}{N + 1} \right)}}}} & (19)\end{matrix}$

The phase angle of the speed harmonic can then be found from therespective phase angles of the N−1 and N+1 order harmonics as:

$\begin{matrix}{\phi_{N} = {\phi_{N} = {\left( \frac{\phi_{N - 1}^{E} + \phi_{N + 1}^{E}}{2} \right) = {\left( {\phi_{N - 1}^{E} + \phi_{1}^{E}} \right) = \left( {\phi_{N + 1}^{E} - \phi_{1}^{E}} \right)}}}} & (20)\end{matrix}$

where:

-   -   φ_(N)=the phase angle of the Nth harmonic of speed    -   φ₁ ^(E)=the phase angle of the fundamental EMF    -   φ_(N−1) ^(E)=the phase angle of the N−1'th harmonic of EMF    -   φ_(N+1) ^(E)=the phase angle of the N+1'th harmonic of EMF

When a resolver harmonic error correlates in harmonic number to aharmonic which is actually occurring in the E-machine, the abovemethodology can be used to distinguish the actual speed variation of theE-machine from that due to resolver harmonic error.

This can be done by expressing (19) and (20) in a complex form anddefining the actual E-machine speed variation as ω_(Nactual) Theharmonic speed error, due to resolver harmonic position error, can befound from measured speed error and ω_(Nactual) according to equation(21) below.ω_(Nerror)=ω_(Nmeasured)−ω_(Nactual)  (21)

where:

-   -   ω_(Nmeasured)=the complex measured Nth harmonic speed variation        from the resolver    -   ω_(Nerror)=the complex actual Nth harmonic speed variation due        to resolver error

The above methodology can be found to work best when EMF data aresampled at discrete time intervals, while operating at a constant speed.However, the above methodology may also be used to correct the measuredharmonic speed data when the engine speed shows an acceleration ordeceleration over the time that the data is collected. By noting the EMFat the first and last measurement, over an integer number ofrevolutions, the values can be assumed to be identical (within thebounds of measurement error). To the extent that they are different, alinear fit can be applied to the speed, and the speed data used in theFourier Transform can be scaled to normalize the data to a constantspeed according to equation (22).

$\begin{matrix}{{\omega(t)}_{adjusted} = {{\omega(t)}_{measured}\left( {1 + {\frac{t}{T}\frac{{EMF}_{final} - {EMF}_{initial}}{{EMF}_{initial}}}} \right)}} & (22)\end{matrix}$

where:

-   -   t=time    -   T=period of the M integer mechanical revolutions    -   EMF_(final)=EMF measured at the final point    -   EMF_(initial)=EMF measured at the initial point

The sampling start and end points may also be chosen to occur at timeswhen the voltage level of the EMF is sufficiently large with respect tothe measurement noise to improve accuracy. In addition, it shall beunderstood that fits of data are possible and contemplated by thepresent disclosure.

The above methodology may also be extended to correct for the angularoffset of the resolver 130 to the phase EMF. The offset is typicallycaused by misalignment of the resolver when mounted to the rotor of theE-machine. If the phase EMF Fourier transform is referenced to theresolver position signal at time zero, then a phase error of the EMF tothe position pulse can be calculated and used to correct for resolverangular misalignment.

It shall be understood that the form of the speed co can be in units ofRPM, radians per second, or any other scaled form of the rotationalvelocity signal received from the resolver 130 and the RDC 140.

While the invention has been illustrated and described in detail in thedrawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly the preferred embodiment has been shown and described and that allchanges, equivalents, and modifications that come within the spirit ofthe inventions defined by following claims are desired to be protected.All publications, patents, and patent applications cited in thisspecification are herein incorporated by reference as if each individualpublication, patent, or patent application were specifically andindividually indicated to be incorporated by reference and set forth inits entirety herein.

What is claimed is:
 1. A system for controlling a vehicle drivetrain,comprising: an electric rotating machine coupled to the vehicledrivetrain; an angular position sensor coupled to the electric machineand configured to generate a sensor output signal indicating an angularposition of the electric rotating machine; a sensor digital convertercoupled to the angular position sensor, the sensor digital converterconfigured to generate a converter output signal using the sensor outputsignal, wherein the converter output signal includes a sensor error dueto the angular position sensor; an error correction controller coupledto the sensor digital converter and configured to analyze the converteroutput using a Fourier analysis to generate a corrected position signalcompensating for the sensor error; and a motor controller responsive tothe corrected position signal received from the error correctioncontroller, the motor controller configured to use the correctedposition signal to operate the electric rotating machine at a firstangular speed.
 2. The system of claim 1, wherein the sensor error ispresent at multiple harmonic frequencies of the angular speed.
 3. Thesystem of claim 1, wherein the error correction converter performs theFourier analysis to determine position and speed components of thesensor error.
 4. The system of claim 1, wherein the sensor error duecomprises a sensor position error which is independent of speed.
 5. Thesystem of claim 1, wherein the sensor error comprises a sensor speederror which is proportionally dependent on speed.
 6. The system of claim1, wherein the converter output signal includes a converter error due tothe sensor digital converter; and wherein the Fourier analysis performedby the error correction controller generates a corrected position signalcompensating for the sensor error and the converter error.
 7. The systemof claim 6, wherein the converter error is dependent on speed and doesnot vary proportionally with speed.
 8. The system of claim 1, whereinthe error correction controller measures a phase EMF signal of theelectric rotating machine.
 9. The system of claim 8, wherein the errorcorrection controller performs a spectral analysis of the EMF signal todetermine one or more harmonics caused by an actual speed variation inthe electric rotating machine.
 10. The system of claim 8, wherein theerror correction controller performs a Fourier analysis of the EMFsignal to determine one or more harmonics caused by an actual speedvariation in the electric rotating machine.
 11. The system of claim 1,wherein the error correction controller distinguishes an actual speedvariation of the electric rotating machine from the first error.
 12. Thesystem of claim 1, wherein the electric rotating machine is a rotatingelectrical motor generator.
 13. The system of claim 1, wherein thevehicle is a hybrid electric vehicle.
 14. The system of claim 1, whereinthe angular position sensor is a resolver.
 15. The system of claim 1,wherein the error correction controller normalizes speed data determinedfrom the converter output signal when the angular speed of the electricrotating machine is changing over time.
 16. The system of claim 1,wherein the error correction controller compensates for an angularoffset of the angular position sensor.
 17. A method for controlling avehicle drivetrain, comprising: using a motor controller to rotate anelectric rotating machine coupled to the motor controller, the electricrotating machine coupled to an angular position sensor, the angularposition sensor generating a sensor output signal indicating an angularposition of the electric rotating machine when the motor controllerrotates the electric rotating machine; generating a converter outputsignal from the sensor output signal using a sensor digital convertercoupled to the angular position sensor and responsive to the sensoroutput, wherein the converter output signal includes a sensor error dueto the angular position sensor; storing converter output signal datarepresenting the converter output signal received from the sensordigital converter over at least one electrical cycle in a memory in anerror correction controller, the error correction controller coupled tothe sensor digital converter; automatically performing a Fourieranalysis on the converter output signal data to generate a correctedposition signal using the error correction controller, the correctedposition signal calculated by the error correction controller tocompensate for the effects of the sensor error; and adjusting themeasured angular speed and position of the electric rotating machineusing the motor controller, wherein the motor controller is coupled tothe error correction controller and is responsive to the correctedposition signal.
 18. The method of claim 17, wherein the sensor error ispresent at multiple harmonic frequencies of said angular speed.
 19. Themethod of claim 17, wherein the error correction converter performs theFourier analysis to determine position and speed components of thesensor error.
 20. The method of claim 17, wherein the sensor errorcomprises a sensor position error which is independent of speed.
 21. Themethod of claim 17, wherein the sensor error comprises a sensor speederror which is proportionally dependent on speed.
 22. The method ofclaim 17, wherein the converter output signal includes a converter errordue to the sensor digital converter; and wherein the Fourier analysisperformed by the error correction controller generates a correctedposition signal compensating for the sensor error and the convertererror.
 23. The system of claim 22, wherein the converter error isdependent on speed and does not vary proportionally with speed.
 24. Themethod of claim 17, comprising: using the error correction controller toautomatically measure a phase EMF signal of the electric rotatingmachine.
 25. The method of claim 24, comprising: performing a spectralanalysis of the EMF signal to determine one or more harmonics caused byan actual speed variation in the electric rotating machine using theerror correction controller.
 26. The method of claim 24, comprising:performing a Fourier analysis of the EMF signal to determine one or moreharmonics caused by an actual speed variation in the electric rotatingmachine using the error correction controller.
 27. The method of claim17, comprising: normalizing speed data determined from the output of thesensor digital converter when the angular speed of the electric rotatingmachine is changing over time.
 28. The method of claim 17, comprising:compensating for an angular offset of the resolver using the errorcorrection controller.
 29. The method of claim 17, comprising: using theerror correction controller to automatically perform a spectral analysison the converter output signal data to determine a magnitude and phaseof the error due to the angular position sensor.
 30. The method of claim17, comprising: using the error correction controller to distinguish anactual speed variation of the electric rotating machine from a resolvererror.
 31. The method of claim 17, wherein the electric rotating machineis a rotating electrical motor generator.